Protective device for use with helmets

ABSTRACT

A protective device for use with a helmet, for example a sporting helmet, has a plurality of removable and replaceable resilient deformable sacrificial bubble structures adapted to be installed on a helmet to absorb an impact force when the impact force impacts the bubble structures. The bubble structures can also provide an indication of location and severity of the impact force on the helmet. In one embodiment, a helmet cover for wearing over an outer surface of a helmet has a base layer capable of being fitted over the outer surface of the helmet and a plurality of removeable and replaceable bubble structures contained in the base layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application U.S. Ser. No. 62/521,304 filed Jun. 16, 2017, the entire contents of which is herein incorporated by reference.

FIELD

This application relates to headwear, particularly to protective headwear such as helmets.

BACKGROUND

Helmets have been used for decades in sports to protect the head from injury that would otherwise occur as a result of an impact to the bare head. The typical helmet is composed of a rigid outer shell and internal padding. The rigid outer shell acts to withstand the contact of an impact force without fracture or damage. The padding internal to the outer shell acts to cushion the impact force and lengthen the duration during which the impact force is applied to the helmet and head so as to reduce the impact force magnitude to below the threshold for injury. A drawback of this design is that the outer shell does little to dissipate or absorb the impact force before it reaches the internal padding so that the impact force may still be sufficient to cause concussion, contusion, laceration or even a skull fracture. Further, when a helmet is exposed to a high impact force, the structure of the entire helmet may be compromised requiring replacement of the helmet.

There remains a need for a device that serves to absorb more of the impact force and to increase the duration of impact prior to the impact force reaching the helmet and the head beneath the helmet, thereby protecting both the helmet and the head from damage.

SUMMARY

In one aspect, there is provided a protective device for use with a helmet, the protective device comprising a plurality of removable and replaceable resilient deformable sacrificial bubble structures adapted to be installed on a helmet to absorb an impact force when the impact force impacts the bubble structures.

In another aspect, there is provided a protective device for wearing over an outer surface of a helmet, the protective device comprising a helmet cover, the helmet cover comprising: a base layer capable of being fitted over the outer surface of the helmet; a plurality of individual pockets formed in the base layer; and, a plurality of resiliently deformable sacrificial elements in the plurality of pockets, the sacrificial elements individually removable from and replaceable in the pockets, the sacrificial elements adapted to absorb an impact force when the impact force impacts the sacrificial elements

In another aspect there is provided a helmet comprising the protective device installed thereon.

Further features will be described or will become apparent in the course of the following detailed description. It should be understood that each feature described herein may be utilized in any combination with any one or more of the other described features, and that each feature does not necessarily rely on the presence of another feature except where evident to one of skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

For clearer understanding, preferred embodiments will now be described in detail by way of example, with reference to the accompanying drawings, in which:

FIG. 1 depicts a rear perspective view of a first embodiment of a protective device in the form of a helmet cover installed on a hockey style sporting helmet;

FIG. 2A depicts a front perspective view of the helmet cover of FIG. 1;

FIG. 2B depicts the helmet cover of FIG. 2A separated from the helmet;

FIG. 3 depicts the helmet cover of FIG. 2 with a base layer partially cut-away to show removable and replaceable resiliently deformable sacrificial elements within pockets of the helmet cover;

FIG. 4A depicts the helmet cover of FIG. 3 without the base layer to show locations of the sacrificial elements arranged on an outer surface of the helmet;

FIG. 4B depicts a rear perspective view of the helmet cover of FIG. 4A;

FIG. 5 depicts an exploded view of the helmet cover of FIG. 4A showing the sacrificial elements separated from the helmet;

FIG. 6A depicts a front perspective view of a second embodiment of a protective device in the form of a helmet cover installed on a hockey style sporting helmet, the helmet cover having a sacrificial element being installed into a pocket thereof;

FIG. 6B depicts a rear perspective of the helmet cover of FIG. 6A; and,

FIG. 7 depicts a front perspective view of a third embodiment of a protective device installed on a hockey style sporting helmet.

DETAILED DESCRIPTION

The present invention provides a protective device for use with helmets, which is installed on an outer surface of a helmet, for example a sporting helmet (e.g. a hockey helmet, a football helmet, etc.), a military helmet or a construction helmet. More particularly, the protective device is adapted to absorb an impact force and to indicate the impact force severity and location when the impact force has been realized on the protective device and the impact force exceeds a predetermined impact threshold. Such functionality is realized by bubble structures in the protective device.

In one embodiment, the protective device may be a single unit comprising a plurality of individual bubble structures, the single unit fitted on to the helmet. The single unit may take the form of a helmet cover having a base layer, the base layer holding the protective device in place on an outer surface of the helmet. In another embodiment, the protective device may be a plurality of individual bubble structures attached directly to the helmet.

The bubble structures are preferably rigid. The bubble structures are preferably hollow or half hollow, more preferably hollow. The bubble structures are preferably resilient. The bubble structures are preferably sacrificial. The bubble structures are preferably individually removable and replaceable. The bubble structures may comprise removable and replaceable deformable sacrificial elements. For example, the bubble structures may comprise cushions, cells or the like. The bubble structures may contain a fluid, for example air at ambient, negative or positive pressure with respect to atmospheric pressure.

The protective device absorbs the impact force of any impact on the outer surface of the underlying helmet by ensuring that the impact contacts with one or a plurality of the bubble structures rather than the helmet itself. The bubble structures may provide complete or partial coverage, preferably complete coverage, of the outer surface of the helmet. Bubble structures having selected deformation properties may be strategically placed at selected locations on the helmet based on susceptibility to injury to a wearer's head at those locations. Optimal locations for the bubble structures will depend on the type of helmet and type of activity.

The bubble structures are configured to deform, crush or rupture when impacted with sufficient force. The bubble structures may deform when the impact force is less than a prescribed lower force threshold and have sufficient resiliency to rebound to original shape without damage after the impact force is removed. The bubble structures may crush permanently when the impact force is above the lower force threshold but below a higher force threshold. The bubble structures may rupture when the impact force is above the higher force threshold. The act of deforming, crushing or rupturing the bubble structures absorbs a portion or all of the impact force before the impact force reaches the underlying helmet. The act of rupturing the bubble structure may result in the release or intake of fluid (e.g. air) depending on the pressure of the fluid in the bubble structure and the type of bubble structure employed. The resulting release or intake of fluid absorbs a further portion of the impact force before the impact force reaches the underlying helmet. Reduction in impact forces can be expressed as an average energy absorption of the bubble structure. During impact, the bubble structure dissipates energy to the surrounding air so that energy is not transferred to the helmet under the protective device, and in turn that energy does not reach a person's head in the helmet. Preferably, the bubble structure provides an average energy absorption of 20% or more of the total energy of the impact.

Further, the crush or rupture of one or a plurality of the bubble structures serves to indicate the location and severity of the impact force. The bubble structures that have been crushed or ruptured are easily removed from the protective device to be replaced with intact bubble structures. The protective device can thereby be used during sport or other activities to withstand multiple impacts to the head. Further, the protective device can be removed from the helmet and installed on another helmet as the need arises to afford additional protection to the other helmet.

In one embodiment, the protective device is a helmet cover having a base layer and a plurality of structures in the base layer. The bubble structures may be contained in a plurality of pockets formed into the base layer of the helmet cover and held in place on the outer surface of the helmet by the base layer. The base layer and/or pockets of the helmet cover preferably comprises a flexible material, for example a flexible fabric. The flexible material may be woven or non-woven. A non-woven material may be, for example, a foam. Flexible materials include, for example, materials that have elastic properties. Some examples of suitable materials include polychloroprene rubber (e.g. Neoprene™), spandex, cotton, cotton-spandex blends, nylon, cotton-nylon blends and the like. The base layer conforms to the outer surface of the helmet when the base layer comprises a flexible material.

Within the base layer, individual pockets are formed configured to contain the bubble structures. The base layer and/or pockets may comprise a stretchable material that can be stretched to accommodate different shapes and sizes of bubble structures placed within the individual pockets. The pockets may be formed by any suitable method, for example by sewing or welding the pockets into the base layer. Each pocket preferably has an opening, for example a seam, either on a surface of the base layer proximal to the outer surface of the helmet or on a surface of the base layer distal to the outer surface of the helmet. The opening may be openable and closable with a closure such as a hook and loop strip (e.g. Velcro™), a snap fastener, a button, a zipper, a drawstring, a magnet or the like. However, the individual pockets may have no closure, in which case the bubble structure may be held within the pocket via the tightness of the walls of the pocket. The opening in each pocket allows the bubble structure to be removed after the bubble structure has been crushed or ruptured so that the bubble structure can be replaced with a new, intact bubble structure. The pockets may have different shapes and/or sizes to prevent installation of an incorrect bubble structure at a given location on the helmet cover.

The bubble structures preferably comprise a material that can be formed, for example molded (e.g. blow molded, injection molded, rotational molded or vacuum thermoformed), into a desired shape. Complete hollow structures may be formed by blow molding or rotational molding. Half hollow structures may be formed with injection molding and vacuum thermoforming. Half hollow structures may be assembled into complete hollow structures by mechanically fastening two half hollow pieces together, for example by welding. Half hollow structures may be used without assembly into complete hollow structures but half hollow structures used in this manner may not have a fluid retention capability. Preferably, the material is formed into complete hollow structures that form the bubble structures. The bubble structures may be filled with a fluid, for example air. The fluid may be at ambient pressure, negative pressure or positive pressure in the bubble structure with respect to air pressure outside the bubble structure. The fluid is preferably at ambient pressure. The fluid is preferably air.

Preferably, the bubble structures comprise a plastic material, particularly a thermoplastic material, for example high density polyethylene (HDPE), medium density polyethylene (MDPE), low density polyethylene (LDPE), polypropylene (PP), polyethylene terephthalate (PET) and the like. Polypropylene is stiffer than high density polyethylene, which his stiffer than low density polyethylene. Average energy absorption of bubble structures made from low density polyethylene is about 32%, but the lesser stiffness may result in opposite walls of the bubble structure touching (“bottoming out”) during an impact. Average energy absorption of bubble structures made from high density polyethylene is about 25%, which is lower than low density polyethylene but HDPE is stiffer mitigating against bottoming out. However, HDPE may exhibit wear after multiple impact events. Average energy absorption of bubble structures made from polypropylene is about 23%, which is lower than LDPE, but the stiffness of polypropylene provides greater resiliency to multiple impacts than HDPE.

The bubble structures are preferably shaped as prisms having rounded corners (i.e. rounded prism shapes). Thus, the edges and vertices of walls of the bubble structures are rounded. The bubble structures have concave proximal surfaces that are proximate the outer surface of the helmet when the helmet cover is installed on the helmet. The bubble structures may also have convex distal surfaces that are farther away from the outer surface of the helmet when the helmet cover is installed on the helmet. The concave proximal surfaces of the bubble structure are complementary to and follow the outer surface of the underlying prior art helmet. The convex distal surfaces of the bubble structures may also be complementary to and follow the contour of the outer surface of the helmet. Lateral surfaces of the bubble structures are preferably generally straight and planar in the form of a rectangle. The lateral surfaces of adjacent bubble structures are preferably parallel with one another. The material that comprises an individual bubble structure is preferably continuous throughout the bubble structure having no joints therein. The distal and lateral surfaces may contain corrugations to stiffen the bubble structure without added material or wall thickness. The bubble structures may contain vent holes to permit fluid (e.g. air) to escape during deformation during an impact. One or more of the size of the vent hole, material properties and physical design features of the bubble structures may be selected to provide differing deformation properties to the bubble structures. The bubble structures may be color-coded to facilitate identification of the type of bubble structure, for example which bubble structures have mild, medium or strong deformation properties. Bubble structures having differing deformation properties may be placed at selected locations on the base layer to provide different impact protection properties at those locations.

With reference to FIG. 1, FIG. 2A, FIG. 2B, FIG. 3, FIG. 4 and FIG. 5, a protective helmet cover 10 is worn on an outer surface 13 of a helmet 12, for example a hockey sporting helmet. The helmet cover 10 comprises of a flexible fabric base layer 11 on which individual pockets 14 are installed, for example by sewing. The base layer 11 fits tightly over the outer surface 13 of the helmet 12. Each of the pockets 14 contain a rigid hollow air-filled cushion 16. The helmet cover 10 thereby holds in place a plurality of the cushions 16 over the outer surface 13 if the helmet 12. The cushions 16 may be inserted into the pockets 14 though open seams 15 (only one labeled) in the pockets 14. The open seams 15 may be openable and closable, if desired, with closing structures, for example hook and loop strips, buttons, elasticized bands, snap fasteners, zippers, magnets and the like.

As shown in FIG. 1 to FIG. 5, the cushions 16 may be arranged with lateral walls 17 (not all labeled) of each cushion configured to be substantially parallel to lateral walls 17 of adjacent cushions, the adjacent lateral walls 17 separated by narrow gaps 18 (only one labeled). The arrangement and configuration of cushions 16 is designed to give substantially complete coverage of the outer surface 13 of the underlying helmet 12. In other embodiments, the cushions may be arranged in different configurations while still maintaining coverage of the outer surface of the helmet.

FIG. 6A and FIG. 6B depict a second embodiment of a protective helmet cover 20, the helmet cover 20 having rigid hollow air-filled thermoplastic cushions 26 (only one labeled) installed into spandex pockets 24 sewn into a base layer 21 of spandex. The air-filled thermoplastic cushions 26 contain air at ambient pressure. The cushions 26 are contoured and have side-walls 27 and grooves 29 formed therein to provide stiffness to the cushions 26 without adding to the weight or wall thickness of the cushions 26. The cushions 26 are insertable into the pockets 24 through open seams 25 (only one labeled) in the pockets 24. The cushions 26 are somewhat larger than the pockets 24 so that once the cushions 26 are inserted in the pockets 24 the spandex tightens around the cushions 26 to secure the cushions 26 in the pockets 24. The pockets 24 are spaced-apart on the base layer 21 to provide narrow gaps 28 (only two labeled) between the cushions 26. In use, the air-filled thermoplastic cushions 26 deform under the force of an impact. If the impact force is less than a first force threshold, the deformed cushion returns to original shape once the force is removed. If the impact force is less than a second force threshold but more than the first force threshold, the cushions 26 are crushed, and must be removed and replaced. If the impact force is more than the second force threshold, the cushions 26 are further ruptured releasing the air inside thereby absorbing at least a portion of the impact force.

FIG. 7 depicts a third embodiment of a protective device 40 installed on an outer surface 41 of a helmet 42, for example a hockey sporting helmet. The protective device 40 comprises a plurality of air-filled cells 46 formed directly on to the outer surface 41 of the helmet 42. The air-filled cells 46 contain air at ambient pressure. Each cell 46 comprises a depression 44 integrally molded into the outer surface 41 of the helmet 42 and a rigid perimeter wall 48 attached to the outer surface 41, for example by welding, and extending from the outer surface 41. Each cell 46 further comprises a flexible thermoplastic cover plate 43 having a perimeter that generally follows a contour of the perimeter wall 48. The cover plate 43 is sized to be seated on the perimeter wall 48 or on a perimetrical lip that follows the contour of the perimeter wall 48. The cover plate 43 is removably secured and possibly sealed on the perimeter wall 48 by a rigid securing ring 45, the securing ring 45 having a perimetrical shape that generally follows the contour of the perimeter wall 48. The securing ring 45 may be secured to the perimeter wall 48 by screws or bolts 51 through first threaded apertures 52 of the securing ring 45, which align with second threaded apertures 53 on the perimeter wall 48 when the securing ring 45 is properly fitted on the perimeter wall 48. The cover plate 43 is held securely between the securing ring 45 and the perimeter wall 48 when installed in the cell 46. The cover plate 43 may be flat or convex depending on the location on the helmet 42 at which the cell 46 is situated. When a cover plate 43 is broken due to an impact force, the securing ring 45 may be removed by removing the screws or bolts 51 and the broken cover plate may be replaced with an intact cover plate 43.

The novel features will become apparent to those of skill in the art upon examination of the description. It should be understood, however, that the scope of the claims should not be limited by the embodiments but should be given the broadest interpretation consistent with the wording of the claims and the specification as a whole. 

1. A protective device for wearing over an outer surface of a helmet, the protective device comprising a helmet cover, the helmet cover comprising: a base layer capable of being fitted over the outer surface of the helmet; a plurality of individual pockets formed in the base layer; and, a plurality of resiliently deformable sacrificial elements in the plurality of pockets, the sacrificial elements individually removable from and replaceable in the pockets, the sacrificial elements adapted to absorb an impact force when the impact force impacts the sacrificial elements.
 2. The device of claim 1, wherein the sacrificial elements are: deformable and able to rebound to original shape without damage after the impact force is removed when the impact force is less than a first force threshold; crushable without being able to rebound to the original shape when the impact force is more than the first force threshold; and, rupturable when the impact force is more than a second force threshold, wherein the second force threshold is higher than the first force threshold.
 3. The device of claim 2, wherein the sacrificial elements when crushed or ruptured provide an indication of location and severity of the impact force on the helmet.
 4. The device of claim 2, wherein the sacrificial elements are half hollow structures.
 5. The device of claim 2, wherein the sacrificial elements are hollow structures filled with a fluid.
 6. The device of claim 5, wherein the fluid is air, the air is under ambient or positive pressure with respect to atmospheric pressure and rupturing the sacrificial elements release the air in the sacrificial elements, the release of the air absorbing at least a portion of the impact force.
 7. The device of claim 5, wherein the fluid is air, the air is under negative pressure with respect to atmospheric pressure and rupturing the sacrificial elements causes an intake of air into the sacrificial elements, the intake of air absorbing at least a portion of the impact force.
 8. The device of claim 1, wherein the base layer comprises a flexible fabric.
 9. The device of claim 8, wherein the sacrificial elements are rigid hollow air-filled cushions.
 10. The device of claim 9, wherein each pocket comprises an opening through which the cushion can be inserted or removed from the pocket.
 11. The device of claim 10, wherein the opening is openable and closable with a fastener.
 12. The device of claim 11, wherein the fastener is a hook and loop, a snap fastener, a button, an elasticized band, a zipper, a drawstring or a magnet.
 13. The device of claim 10, wherein the pockets comprise a flexible pocket fabric sewn into the base layer and the cushion is held in the pocket by tightness of the flexible pocket fabric when the cushion is inserted in the pocket.
 14. The device of claim 10, wherein the flexible fabric of the base layer and the flexible pocket fabric are stretchable and the pockets can be stretched to accommodate different shapes and sizes of the cushion within the pocket.
 15. A helmet comprising the protective device of claim 1 installed thereon.
 16. The helmet of claim 15, wherein the helmet is a sporting helmet.
 17. A protective device for use with a helmet, the protective device comprising a plurality of individually removable and replaceable resilient deformable sacrificial bubble structures adapted to be installed on a helmet to absorb an impact force when the impact force impacts the bubble structures.
 18. The device of claim 17, wherein the bubble structures comprise a plurality of air-filled cells formed directly on the outer surface of the helmet.
 19. The device of claim 18, wherein the air is at ambient pressure and each cell comprises: a depression formed in the outer surface of the helmet; a rigid perimeter wall around the depression attached to and extending from the outer surface; and, a flexible thermoplastic cover plate removably secured on the rigid perimeter wall.
 20. The device of claim 17, wherein each bubble structure is removable and replaceable individually on the helmet when the bubble structure is damaged. 